Brush machinery and brush constructions

ABSTRACT

TAINING TUFT-FORMING DEVICES WHICH WHEN INSERTED INTO SAID STOCK BOX WILL PICK AND TRIM THE DESIRED TUFT CONFIGURATION OF ANY BRUSH COMPONENT.   THIS INVENTION, CONSISTING OF A NEW AND USEFUL BRUSHMAKING APPARATUS, ALLOWS TUFTED BRUSH COMPONENTS TO BE MANUFACTURED HAVING PRETRIMMED SYNTHETIC FILAMENT TUFTS. SAID APPARATUS IS CAPABLE OF PICKING AND TRIMMING ALL THE DESIRED TUFTS REQUIRED IN A SINGLE BRUSH CONSTRUCTION SIMULTANEOUSLY, AND FURTHER, SIMULTANEOUSLY INSERTING ALL THE TUFTS INTO THE CONSTRUCTION. THE APPARATUS COMPRISES A SUITABLE FILAMENT STOCK BOX FOR DISPENSING CUT-TO-LENGTH SYNTHETIC FILAMENT AND A PICKING UNIT CON-

Aug. 1, 1972 J. c. LEWIS, JR

BRUSH MACHINERY AND BRUSH coNsTRUcTIoNs 5 sheets-Sheet 1 'original Filedsept. 12, 196e 7A lo" W diag.

` Allg. 1, 1972 J, C, LEWlS, JR Re.

BRUSH MACHINERY AND BRUSH CONSTRUCTIONS Original Filed Sept. 12, 1966 5Sheets-Sheet 2 rm/E/v fog -l1g. 1, 1972 v 1 CI Ewls, JR l RC. 27,455

BRUSH MACHINERY AND rBRUSH coNsTRucToNs 5 sheets-sheet s Original FiledSept. l2, 1966 IN1/EN ro R I.Al-lg. 1, 1972 1 C LEWIS, JR Rt. BRUSHMACHINERY AND BRUSH CONSTRUCTIONS I Original Filed Sept. l2, 1966 5Sheets-Sheet 4.

Allg. l, 1972 1 C, L E- WlsI JR R.

BRUSH MACHINERY AND BRUSH CONSTRUCTIOS Original Filed Sept. 12, 1966 5Sheets-Sheet 5 I INVENTOR. ,4 y V k/oa ewzlg ./f:

United States Patent O 27,455 BRUSH MACHINERY AND BRUSH CONSTRUCTIONSJohn C. Lewis, Jr., Middlebury, Vt., assignor to Tucel Industries, Inc.,Middlebury, Vt. Original No. 3,471,202, dated Oct. 7, 1969, Ser. No.578,840, Sept. 12, 1966. Application for reissue Dec. 2s, 1970, ser. No.101,202

Int. Cl. A46d 1/08 U.S. Cl. 300-2 35 Claims Matter enclosed in heavybrackets appears in the original patent but forms no part of thisreissue specification; matter printed in italics indicates the additionmade by reissue.

ABSTRACT OF THE DISCLOSURE This invention, consisting of a new anduseful brushmaking apparatus, allows tufted brush components to bemanufactured having pretrimmed synthetic filament tufts. Said apparatusis capable of picking and trimming all the desired tufts required in asingle brush construction simultaneously, and further, simultaneouslyinserting all the tufts into the construction. The apparatus comprises asuitable filament stock box for dispensing cut-to-length syntheticfilament and a picking unit containing tuft-forming devices which wheninserted into said stock box Will pick and trim the desired tuftconfiguration of any brush component.

This invention relates to new and useful brush-making machinery. Morespecifically, it is concerned with machinery for continuouslyfabricating modular brush components. It also includes novel brushconstructions and methods of manufacture.

The brushv industry and the brush-making art during the last fifty yearshas remained, for the most part, unchanged. The only major changestaking place have been in the substitution of synthetic monof'ilaments(thermoplastic fibres, i.e., nylon monofilament) for the vegetable andhair fibres previously employed. The emphasis has been on finding waysto substitute directly the synthetic for the natural, utilizing the samebrush-making equipment, i.e., stapling machinery and little or no effectplaced upon improving the methods and machinery used. Great strides havebeen made wherein two or three brushes can be stapled simultaneously,however, it still requires one picking and stapling cycle for each fibretuft staple-set in the brush back. In this area, there has been noadvancement toward finding a way of placing all the desired tufts in abrush back simultaneously; and performing this feat in the same amountof time required to pick and staple-set one fibre tuft employingconventional brush machinery.

The need to improve the machinery for fabricating brush components canbe illustrated by comparing and describing conventional brush-makingmachinery with the machinery of this invention. The brush-makingmachinery of this invention differs from ordinary brush machinery inthat it employs a new method of picking fibre tufts. The conventionalstapling machine employs a picker which removes a fibre tuft from astock or feed box by first entering the stock box approximately at itsmidsection (lateral to the parallel fibre) and picking a given amount offibre at the fibres midsection. The picker then proceeds to transportthe predetermined v01- ume of parallel fibre to a means for doubling thefibre at its midsection (prior to stapling), thus resulting in a tufthaving a U-shape wherein both ends of each individ-V ual fibre arelocated at the working tip of the resultant Re. 27,455 Reissued Aug. 1,1972 tuft. A staple or [anochor] anchor (wire member) is then insertedthrough the U-shaped loop land the tuft then forced into a predrilledhole in a brush back. Each tuft is formed in this manner one afteranother until the necessary number of holes have been filled.

The picking device of the machinery of this invention works on anentirely different principle. The picker or picking unit enters thefibre stock box from the end (longitudinal to the fibre) and engages thefibre from the end, thus instantly forming, a fibre tuft. The fibreemployed in forming tufts in this manner is one-half the original lengthof the fibre required using the conventional picking method. Theinstantly formed fibre tuft is then automatically inserted into a brushback. The resultant fibre tuft can be anchored in many Ways; i.e., heatsealed, set in epoxy, and the like. However, the preferred method is toheat seal the fibre tuft. This can be done either prior to inserting thetuft into the brush back 0r after inserting the tuft through a portionof the brush back. Fibre tufts formed in this manner are anchoredsecurely within the brush back and can not be removed.

Since, when forming tufts using this new and novel method of picking,there is no requirement for doubling the fibre prior to insertion intothe brush back, tufts so formed in accordance with this inventionrequire no trimming. This results in an appreciable savings to thebrushmaker. A second economic savings is also realized, that being theelimination of the staple or anchor.

It is of particular importance in this invention that the picking deviceemployed operates in such a manner that at least two fibre tufts aresimultaneously formed. However, the preferred cycle of picking is one inwhich a complete brush component is formed simultaneously by employing aseries of picking devices (hereinafter referred to as a picking unit)set in a prearranged pattern and heat sealing al1 the fibre tuftsinstantly, thus forming a brush in the same cy-cling time it takes topick and staple-set one fibre tuft using the conventional machinery.

Objects and advantages of the invention will be set forth in parthereinafter and in part will be obvious herefrom, or may be learned bypractice with the invention, the same being realized and attained bymeans of the methods, combinations, compositions and improvementspointed out in the appended claim.

The invention consists in the novel steps, methods, combinations,compositions and improvements herein shown and described.

The objects of this invention will now be described. While the inventionis primarily concerned with new and novel brush machinery, it should berealized that the principles of this invention are attained only throughthe novel method of picking and forming fibre tufts, and theseprinciples are applicable to situations wherein: (1) single fibre tuftsare formed, (2) multiple fibre tufts are formed, (3) complete brushcomponents are simultaneously formed, and (4) continuous modular brushcomoponents are formed.

It is, therefore, an object of this invention to provide new and usefulbrush-making machinery. Another object of this invention is to providean automatic brush machine which can form more than one fibre tuftsimultaneously. A further object of this invention is to provide anautomatic brush machine which will simultaneously pick fibre tufts,assemble the tufts in a predetermined pattern and form an integral fibretuft/brush support modular brush component. A still further object ofthis invention is t0 provide a brush machine of the type set forth inthe foregoing object wherein the picking unit comprises an assembly ofindividual tuft pickers arranged in a predetermined tuft patternallowing the complete fibre portion of the brush component to be formedsimultaneously.

Another object of this invention is to provide a brush machinecomprising means for heat sealing libre tufts integral with a brushsupport. A still further object of this invention is to provide a brushmachine which assembles cut-to-length thermoplastic libre into libretufts wherein no trimming of the tufts is required.'Yet still a furtherobject of this invention is to provide a brush ma- :hine as set forth inthe foregoing object wherein the original length of the` fibre employedis nearly the same as the finished libre tuft, and not double the lengthas is true with the staple-set U-loop tuft.

Another o bject of this invention is to provide a novel and new pickingdevice.

Another object of this invention is to provide a Ibrush machinecomprising at least two different size tuft picking devices, the pickingdevices so arranged in the picking mit, that at least two different sizebre tufts can be simultaneously formed. Yet a further object of this in-Iention is to provide a brush machine of the type 'set orth in theforegoing object wherein at least two different length tufts aresimultaneously formed. A still further obect of this invention is toprovide a brush machine comarising at least two dilferent feed stockboxes, thus allowlng for forming brush components having more than oneype of fibre tuft, and/ or more than one color libre tuft.

Another object of this invention is to provide a novel rush constructioncomprising heat sealed synthetic fibre nftS. A further object of thisinvention is to provide i tufted brush construction comprising at leasttwo differ- :nt size heat sealed tufts, said tufs being formed from:hermoplastic libre having an original length only slightly onger thanthe length of the finished fibre tuft. Yet still i. further object ofthis invention is to provide a tufted )rush construction comprising heatsealed ber tufts possessing different trims wherein the tufts are set insuch t pattern as to be opposing one another.

Further objects of this invention are to provide novel :methods for theproduction of tufted brush construction, ind brush constructionsemploying some of the features )f the types set forth in the foregoingObjects.

In the drawing:

FIGURE 1 is a longitudinal sectional view of a tuft forming picker ofFIGURE 6 containing parallel synthetsectional view taken along line1A-1A of FIGURE 1.

FIGURE 2 is a longitudinal sectional View of another luft forming pickerof this invention having an internal venturi section. FIGURES 2A and 2Bare cross-sectional views taken along lines 2A-2A and 2B-2B,respectively, of FIGURE 2.

FIGURE 3 is a longitudinal sectional view of a tuft forming picker ofthis invention having a square crossiectional construction. FIGURE 3A isa cross-sectional View taken along line 3A--3A of FIGURE 3. Y

FIGURE4 is a longitudinal sectional view of a tuf forming picker of thisinvention having a star-like crossiectional construction. FIGURE 4A is across-sectional /iew taken along line 4A-4A of FIGURE 4.

FIGURE 5 is a longitudinal sectional view of a tuft forming picker ofthis invention having a triangular cross- ;ectional construction. FIGURE5A is a cross-sectional Iiew taken along line SA-SA of FIGURE 5.

FIGURE 6 is a longitudinal sectional view of a tuft Forming pickerhaving an internal tapered section in ac- :ordance with this invention.FIGURES 6A, 6B and 6C ire cross-sectional views taken along lines 6A-6A,6B 5B and 6C-6C, respectively, of FIGURE 6.

FIGURE 7 is a longitudinal sectional view of thetuft :'orming picker ofFIGURE 6 containing parallel synthec libre in accordance with thisinvention. .FIGURE 7A s a cross-sectional view taken along line 7A-7A ofFIGURE 7.

,FIGURE 8 is a longitudinal sectional view of a tuft :'orming picker inaccordance with this invention which s employed to form a shaped end ona libre tuft.

FIGURE 9 is a perspective View illustrating how the tuft forming pickerof FIGURE 8 may be employed to form a predetermined quantity ofindividual parallel synthetic fibres into a tuft.

FIGURE 10 is a perspective view of a tuft as formed in accordance withthis invention with one end heat sealed which forms the tuft base andthe other end possessing a rounded trim.

FIGURES 11, 12 and 13 are longitudinal sectional views of tuft formingpickers "illustrating other shapes which may be imparted to tufts inaccordance with this invention.

FIGURE 14 is alongitudinal sectional view of a group of tuft formingpickers in accordance with this invention illustrating libre ends priorto tuft-end formation. v

FIGURE 15 is a longitudinal sectional view of` one of the tuft formingpickers of FIGURE 14 containing a heat sealed libre tuft as formed inaccordance with this invention.

FIGURE 16 is a sectional view in cross-section of a brush back withtufts as formed in accordance with this invention.

FIGURE 17 is a detailed fragmentary view in perspective and partly insection showing one arrangement of the tuft forming pickers, a syntheticbre storagehopper, a heat sealing die and a brush back/fibre tuftassembly station in accordance with this yinvention wherein the tuftforming pickers are opposite the fibre istorage hopper. FIGURES 18 and19 lare further extensions of FIG- URE 17 wherein the tuft formingpickers are opposite the heat sealing die and the brush back/ bre tuftassembly station respectively. i

FIGURE 2O is a side cross-sectional yview taken along line AA-AA inFIGURE 17 of one arrangement of the tuft forming pickers employed toform a brush in accordance with this invention.

FIGURE 21 is a side cross-sectional view taken along line BB-BB oflFIGURE 17 of the synthetic fibre storage hopper. Y

FIGURE 22 is a side cross-sectional view taken `along line CC-CC inFIGURE 17 of the heat sealing die. u

FIGURE 23 is a side cross-sectional View taken along line DD--DD inFIGURE17 of a brush back and brush back mounting support.

FIGURE 23A is a side cross-sectional view taken along line EE-EEinFIGURE 19 illustrating a brush with tufts made according to thisinvention. 'l

FIGURE 24 is a perspective View illustrating how the tuftpformingpickers of FIGURE l may be employed to form a continuous tuftedstrip-brush construction.

FIGURE 25 is a perspective view of a strip-brush made according to themanner illustrated in FIGURE 24v.

In order to describe the invention more fully, Vreference is now made tospecific embodiments illustratedbin the drawings. The invention isdirected to brush making wherein tufted brushes are formed employingtuftforming pickers in such a manner that'each tuft contained 'in the brushback is simultaneously picked, simultaneously prepared for insertion asa heat sealed tuft into a brush back thus forming a complete brush inthe same instant of time it requires an ordinary lbrush machine to pickand staple-set one libre tuft. This new and novel way to pick iibretufts is achieved by employing ay longitudinal tube having a definiteshape, i.e., circular cross-section, and limiting its inside length tothat of somewhat less than the length of the libre used forforming a'fibre tuft. Such'tuft forming pickers are shown in FIGURESY 1 through5. ,i y

The tuft forming picker 1 of FIGURE 2 has a venturi section 4approximately midway along the internal wall as indicated by line2B--2B. As seen in FIGURE 2B, the venturi section is constructed suchthat it is constricted thus forming a smaller opening 2 at line 2A-2A.When libre enters the opening at 2, it is allowed to flow along thetube-like picker and as the fibre approaches the venturi at 4, the libreis further compressed in order to tighten the unsealed fibre tuft whichresutls in holding the fibre together more rmly in order that they maynot fall away. The tapered pin section at 3 provides the means forholding the tuft forming picker in any suitable mounting device.

By employing tuft forming pickers of the type shown in FIGURES 1, 3, 4and 5 it is possible to form tufts having different shapes. It should beappreciated that other shaped cross-sections can be employed withoutdeviating from the scope of this invention.

A more suitable type of tuft forming picker of this invention is shownin FIG-URE 6 wherein the exterior surface of the picker has a section at7 having a slightly larger diameter which serves to minimize frictionbetween the fibre and the external wall during removal of the tuftforming picker from the stock feed box. A tapered section is placed at 9allowing fibres to first enter the picker at 8, travel through theinternal section up to 9 and stop at the trim forming end, 5. The shapeor contour of will determine the trim of the finished bre tuft. Thesmaller diameter at 9 acts in much the same way the venturi does inFIGURE 2. The tapered pin section 6 provides means for support of thepicking device.

FIGURE 7 shows the tuft forming picker of FIGURE 6 containing syntheticfibre 10 in parallel arrangement. The end of the fibre 10 is slightlycompressed together due to the internal taper at `9. Fibre end 10projects somewhat beyond the end of the tuft forming picker; this end10" will eventually form the heat sealed portion of the fibre tuft. Bycontrolling the length of both the fibre and the tuft forming picker, itis possible to form tufts having different trim lengths and heat sealedportions.

FIGURES 8, 9 and 10 illustrate how a heat sealed tuft 11 can be formedpossessing a rounded trim without having to physically trim the tuft.Fibre 11 in parallel arrangement is inserted into the tuft formingpicker and the ends 12 conform to the interior end 12 of the picker.This results in the opposite end 12 conforming to the shape of a concavecontour. The sealed fibre tuft will have a fibre length the same as thelength for that of the interior of the picker. The excess fibre ends 12as shown in FIGURE 9 extend outwardly from the tuft forming picker forsuch a length which makes them desirable for heat sealing. FIGURE 10shows the finished libre tuft after having been heat sealed at 12" inFIGURE 9 possessing a rounded trim 12 and a heat sealed tuft end 13.

FIGURES 11, 12 and 13 illustrate different interior configurations whichcan be employed for forming different trims in fibre tufts. The fibre-14 in FIGURE l1 conforms to the interior shape at 14', likewise, libres1S and 16 of FIGURES 12 and 13 respectively conform to the interiorshapes at and 16.

In order to form a heat sealed tuft like t'he one shown in FIGURE 10 itis necessary to heat the end portion of a group of parallel fibres to atemperature of approximately to that of the melting point of theparticular type of synthetic fibre employed. Most thermoplastic fibreshave softening points which make them pliable and capable of fusingtogether under a slight pressure. In the case of oriented syntheticfibres, they usually begin to deorient at their softening temperature,thus causing a decrease in length and an increase in diameter.Consequently, as the heated oriented ends of the fibre soften, they mustbe shaped and made to fuse in order to create a self-supporting heatsealed tuft. It is usually convenient to cause the fibre ends to becomesoftened while contained within a heated shaping mold. In FIGURE 14 thetuft forming picker 17 containing fibre 18 is moved in the direction Dcausing the libre ends 18 to enter the heated shaping lmold at 19, thesection 19 being more or less a guide means, and filling the cavity 20of section 20. The tuft forming picker is allowed to remain in thisposition long enough for the fibre ends 18 to become fused and shapedlike the tuft end 18" of FIGURE 15. The cavity section 20 of FIGURE 14can be fashioned from stainless steel, however, Teflon (the trade namefor a polyliuoride polymer made by Du Pont) makes a much more suitablematerial. The heating means 21 can be set at such a temperature that thetime lag of the bres entry of the end 18' into the cavity 20 will causethe fibres to fuse but not melt. It is desirable, after fusing thefibres together and imparting the desired shape to the fused portion, toimmediately insert the still softened end 18 into a predetermined tufthole 22 in a brush back 23 of FIG. URE 16 causing the end 18" to takethe form of the tuft hole. After insertion into the tuft hole, thesoftened fused portion takes a new shape 18' and becomes solid uponcooling. When the tuft forming picker 17 is drawn away the heat sealedfibre tuft 24 is left exposed and is securely anchored in the brush backWithout the aid of the conventional Wire anchor or staple.

While the invention is susceptible of embodiment in many differentforms, there is shown now in FIGURES 17, 18 and 19 specific embodimentswith the understanding that the present disclosure is to be consideredas an exemplification of the principle of the invention and is notintended in any way to limit the invention to the embodimentsillustrated.

Particular attention is now given to the automatic brush machine shownin FIGURES 17, 18 and 19. Tln's automatic unit consists of three basicforming stations; a synthetic fibre stock box 25, a heating unit forforming the heat sealed libre tuft ends 26 and a mounting fixture forthe brush back 27. The tuft forming picking device 31 in FIGURE 17 iscomprised of individual tuft forming pickers 29 and 29 havingconfigurations like the tuft forming pick of FIGURE l. Outer tuftforming pickers 29 are larger in diameter than the inner tuft formingpickers 29 as shown in FIGURE 20. By having larger diameter tuft formingpickers, a brush may result having larger tufts positioned around itsouter parameter. The tuft forming pickers 29 and 29 in the formingdevice 31 are arranged in such a manner so as to conform to the tuftarrangement desired in the finished brush. Picking is carried out byallowing the picking unit 31 to enter longitudinally to the bres lengthinto the stock box 25 as shown in FIGURES 17 and 2l, through fibreretaining holes 28 and 28. The pickers first come into contact with theends of the fibre 30 and by employing a quick entry in the direction ofE the fibres are forced into the interior cavity of each tuft formingpicker. Upon reversing the motion of the picking unit 31 the individualtuft forming pickers retract, each filled with a predetermined amount ofsynthetic libre. As the picking unit leaves the fibre stock box morefibre 30 falls so as to occupy the empty spaces created by the removalof fibres 30. Suitable means may be employed for vibrating the fibrestock box in order to facilate fibre alignment and mobility. Aftercompleting the picking operation, the machine support 32 is indexedforward in the direction F in order to allow the heating unit 26 toalign itself opposite the tuft forming picking unit, as shown in FIG-URES 1'8 and 22. The picking unit is moved forward 1n the direction Guntil the fibre contained in each tuft forming picker comes into contactwith the cavities 34 and 34 of the shaping mold 33. This shaping mold ispreferably constructed from Teflon thermoplastic polymer. The mold isattached to a steel mounting plate 36 containing suitable electricheating elements 35. The fibre ends become heated and shaped in the samefashion as previously described and shown in FIGURE 14. Preferably, thefibre 30 is inserted into the cavities and allowed to become heated for5-10 seconds while the actual temperature of the cavities is kept higherthan the melting point of the fibres; i.e. isotactic polypropylenefibres melt in the range from to 145 degrees centigrade (100,000 to200,000 molecular weight polymer). The cavities in this case might bekept at temperatures in the order of from to 160 degrees centigrade.After the :nds of the libre tufts have been heat sealed, the pickinglnit 31 is reversed allowing the tuft heat sealed por- ;ion to come awayfrom the cavities. This removal can be acilitated by rst applying a moldrelease to the inner iurfaces of the mold cavities. However, if Teflonis em- )loyed for the cavity structure, a mold releasing agent s notnecessary. The machine support 32 is indexed foraard in the direction Hin order to align the brush supaort 36 opposite the heat sealed (stillmoldable) fibre .ufts. In FIGURES 19 and 23 the picking unit is thenidvanced forward in the direction of I whereupon the ltill moldablefibre tuft ends are inserted into the caviies 39 and 39 of the brushback 38. As the tuft ends :ome into contact with the cavities, themoldable end :onforms to the cavity contour and cools. The brush Jack isheld against the brush support by means of fix- :ures 37. Upon reversingthe picking unit 31 in the direc- :ion J the tuft forming pickersrelease the fibre and the )verall result is a finished brush as shown inFIGURE 23A. The brush back 38 has heat sealed fibre tufts 30"'. Phepreferred time taken for the complete fabrication lof :he brush isapproximately ten seconds. However, there s no definite time cycle. Eachcycle depends upon the ;ype of synthetic fibre employed and the size ofthe fibre uft desired. There is no trimming required after forming hebrush of this invention since there is no disalignment )f fibres whenforming the fibre tufts. This is true because here is no doubling offibres prior to insertion.

By employing tuft picking units as shown in FIGURE Z4 it is possible toform continuous modular strips of hermoplastic tufted brushconstructions. In order to ichieve this, it requires an assembly of tuftforming pick- :rs 39 arranged side by side in a line. After the fibre 44.s inserted in the tuft picking unit, the unit is then moved :oward theforming mold 40 in the direction K thus alowing the fibre ends 44 tolbecome softened and fused Nithin the cavity 41. The mold 40 is attachedto a steel rousing 43 which contains suitable heating elements 42. Uponcooling of the fused fibre ends 44' the molded :onstruction 45 isindexed forward in the direction L illowing the picking unit to repeatits cycle. When this Jperation is carried out properly, the modularbrush con- ;truction 45 as shown in FIGURE 25 results.

The tuft forming pickers of this invention can be con- ;tructed from anyof the conventional metal elements or illoys known to man. Also, it ispossible to construct the vnicking devices from thermoplastic materials;i.e., poly- Jropylene, polyacetal, polyamide, and the like. The tuft:`orming pickers are not limited to any given size since hey Ican haveany length and internal diameter so long is they conform to a givenfibre tuft.

It has been found that the tuft forming pickers of this nvention willpick tufts from assembled parallel cut-to- ,ength synthetic fibreshaving any cross-sectional shape; .e.,` circular, X-shaped, star shaped,hollow, and the like. Phe diameter of the fibres picked range from 0.008inch o 0.250 inch. The lengths of the cut-to-length fibre can ange from0.5 to 30 inches. The compositions o-f the synthetic fibre picked andassembled into fibre tufts is lot limited, and thermoplastic fibreseither oriented or moriented can be used to form tufts in accordancewith ',he invention. Polymers like polyamide, polypropylene,nolyethylene, co-polymers of polypropylene and ethylene, polyfiuoride,and the like can be employed.

If more than one fibre stock box is employed, it is possible to pick onecolor and diameter fibre during one gicking step, and another color anddiameter during a iecond picking step and then instantaneously heat seal1nd assemble the combination of fibre tufts into a brush sack. 'f

The foregoing considerations conclusively demonstrate he advantages tobe gained by providing picking devices )f the type hereinbefore,descrided. When such picking ievices are incorporated into` automaticbrush making equipment there is attained new and novel brush con#structionsheretofore not known. -1 C The invention in its broaderaspects is not limited to the specific steps, methods, compositions,combinations and improvements described but departures may be madetherefrom in the scope of the accompanying claims without departing fromthe principles of the invention' and without sacrificing its chiefadvantages.

I claim:

1. Brush-making apparatus for assembling a plurality of syntheticfilaments comprising a filament storage box having an openingforfilling, and a plurality of apertures in the front face disposed in abrush tuft' configuration; and a picking device 'comprising a pluralityof hollow cylindrical tuft forming pickers corresponding in size, shape,and number to said apertures ini said boxface and extending from thepicking device in parallel relation corresponding to. said brushtuftconfiguration of said box apertures; each said hollow cylindricalpickerv having a closed end forming meansV for securing filamentpickers' to said device, an internal constriction, and an open endhaving a tapered edge, and being ofay length less than the length of afilament; whereby when said tuft forming pickers are inserted andremoved from said apertures in said storage box filled with brushfilaments, saidl pickers will Vsimultanebusly pick and vtrim tufts offilaments for assembly into a brush. Y'

2.V A brush making apparatus for assembling synthetic #laments formounting in a brushback comprising:

' a stock box for supporting a plurality 'of synthetic cutfl to-lengthfilaments in a parallel relationship, said box having a wall with atleast one aperture itherein, the wall extending transverse to thelongitudinal axis of the filaments at an yena thereof when saidfilaments are supported in said box, the aperture being larger than thecross'sectional area of at least one of the said vlaments; v

at least one hollow picking element having an open,

filament-receiving end and a closed end, said elementv adapted to beinserted into said box through the aperture to pick at least onefilament tuft from said box so that when said box supports saidfilaments and said element is vinserted therein, said element willreceive at least one filament and thereby forml a filament tuft; p l Ymeans carried by said picking element for-retaining the pickedtuft'therein; p." whereby when the open end of said pickingelement isinserted intoI said box through said aperture to receive at least onefilament therein, and said element and retained tuft are subsequentlywithdrawn from said box a tuft will be picked from said box for Ymounting in a brushback. l .v 3. The device of claim 2 wherein saidpicking element is adapted to simultaneously pick a plurality offilaments from said box when said element is inserted through saidaperture to forma tuff comprising a plurality of filaments. v

4. The device of claim 2 wherein the wall of said box has a plurality ofapertures mutually-spaced in-,pre-v selected positions and a pluralityof said picking. elements are provided for simultaneousv insertion intosaid box through the apertures to pick a plurality of tufts from saidboxjor mounting in a brushback. 5. Brush making apparatus for assemblingsynthetic filaments for mounting in a brushback comprising:v

a stock box for supporting a plurality o1 cut-to-length syntheticfilaments in a parallel relationship, said box having at least oneaperture in a wall thererojc so that when said box supports saidfilaments` said wall is perpendicular vto thelongitudinal axis of thefila- .i ments and said aperture exposes the ends of a plu-V y, ralityof said filaments; at least one elongatedkhollow picking element havingan open filament-receiving end anda closed tufttrimming end, saidelement adapted to be inserted into said box through said aperture toreceive the end and central portion of a plurality of filaments whensaid filaments are supported in said box, the end portion of saidfilaments abutting the internal face of the closed end of said element,to form a tuft of said filaments;

retaining means carried by said picking element for retaining the endand central portion of said tuft in said element when said element iswithdrawn through said aperture.

6. The device of claim 2 wherein the retaining means carried by saidpicking element is mounted within said element and comprises means forcompressing said tuft.

7. The device of claim 5 wherein the retaining means carried by saidpicking element is mounted within said element and comprises means forcompressing said tuft.

8. The device of claim 6 wherein the retaining means is an internalconstriction disposed adjacent the internal wall of said closed end.

9. The device of claim 6 wherein the retaining means is an internalconstriction spaced from the internal wall of said closed end.

10. The device of claim 7 wherein the retaining means is an internalconstriction disposed adjacent the internal wall of said closed end.

11. The device of claim 7 wherein the retaining means is an internalconstriction spaced from the internal wall of said closedend.

12. The device of claim 5 wherein the internal wall of said hollowpicking element has a lateral cross section in a pre-selectedconfiguration so that when said element receives said filaments, saidelement will form a tuft of filaments having a corresponding lateralcross-sectional configuration.

J3. The device of claim 12 wherein the pre-selected configuration is asquare.

14. The device of claim 12 wherein the pre-selected configuration is astar.

15. The device of claim 12 wherein the preselected configuration is atriangle.

16. 'The device of claim 12 wherein the pre-selected configuration iscircular.

17. The device of claim 5 wherein the internal wall of the closed end ofsaid hollow picking element has a preselected configuration to trim theend of said tuft formed thereby.

18. The device of claim 17 wherein the pre-selected configuration isconvex.

19. The device of claim 17 wherein the pre-selected configuration isconcave.

20. The device of claim 17 wherein the pre-selected configurationcomprises a plurality of stepped surfaces.

21. The device of claim 5 wherein the internal face of the closed end ofsaid hollow picking element lies in a plane disposed at an angle to thelongitudinal axis of said picking element. Y

22.' The device of claim 5 wherein the external surface of said pickingelement immediately adjacent the open, filament-receiving end is taperedtoward said open end, and the opening described by the terminal portionof the surface is perpendicular to the longitudinal axis of saidelement.

23. The device of claim 5 wherein the filament-receiving opening of saidpicking element is disposed at an angle to the longitudinal axis of saidelement.

24. The device of claim 23 wherein the external surface surrounding theopening lies in a plane disposed at an acute angle to the longitudinalaxis of said picking element.

25. The device of claim 23 wherein the external surface surrounding theopening lies in a plane disposed perpendicularly to the longitudinalaxis of said picking element.

26. Apparatus for assembling synthetic filament tufts 10 having a fusedend portion for mounting on a brushback comprising:

a stock box for supporting a plurality of cut-to-length synthetic)laments in a parallel, stacked relationship, said box having at leastone aperture therein for exposing the ends of a plurality of saidfilaments;

at least one hollow picking element having an open, filament-receivingend and a closed, tuft-trimming end, the open end of said elementadapted to be inserted into said box through the aperture and to receivean end and central portion of a plurality of filaments therein, forminga tuft;

retaining means carried by said picking element for retaining said tuftof filaments therein when said element is withdrawn from said stock boxthrough the aperture;

heated mold means having at least one tuff-receiving recess therein forreceiving an end portion of said tuft retained in said picking elementand for fusing said end to form a tuft of filaments extending from anintegral fused base adapted to be mounted on a brushback;

so that when said picking element is inserted into said stock boxthrough said aperture to pick a tuft of filaments, and withdrawntherefrom with the tuft retained therein, the end portion of said tuftextending from said picking element may be inserted into the recess ofsaid heated mold means until said end is fused for mounting said fusedend on a brushback.

27. The device of claim 26 wherein said stock box has a plurality ofapertures; said heated mold means has a plurality of recesses, theapertures and recesses being arranged in a pre-selected configurationand; a plurality of picking elements are provided; said picking elementsadapted to be simultaneously inserted into said box through saidapertures, to pick a plurality of tufts from said stock box, andsubsequently, to simultaneously insert the end portions of said tuftsextending therefrom into said recesses to fuse the end portions formounting on a brushback.

28. The device of claim 26 further comprising means for supporting abrushback having a plurality of tuftreceiving holes therein disposedadjacent said mold means in a cooperating relationship therewith so thatthe fused end portion of said tuft may be withdrawn from the recess insaid heated mold means and inserted into a hole in said brushback beforesaid fused end cools so that said tulft end cools in said holeconforming to the internal confines thereof to retain said tuft in Saidbrushback.

29. The device of claim 27 further comprising means for supporting abrushback having a plurality of tuftreceiving holes therein disposedadjacent said mold means in a cooperating relationship therewith so thatthe fused end portions of said tufts may be withdrawn from the recessesin said heated mold means and inserted into holes in said brushbackbefore said fused ends cool so that said tuft ends cool in said holesconforming to the ntenal confines thereof to retain said tufts in saidbrush- 30. Apparatus for assembling a plurality of filament tufts toform a brushback having said tufts extending from an integral back offused filamentary material comprising:

a stock box for supporting a plurality of cut-to-length syntheticfilaments in a parallel, stacked relationship, said box having aplurality of apertures therein for exposing the ends of a plurality offilaments;

a plurality of hollow picking elemen'ts each of said elements having anopen filament-receiving end and a closed ruft-trimming end, the open endof each element adapted to be inserted into said box through theaperture and to receive an end central portion of a plurality offilaments therein forming a tuft;

retaining means carried by each of said picking elements for retainingsaid tufts of filaments therein when said element is withdrawn from said'box through th aperture; v

l heated mold means having a tuft-receiving recess, said recess havingthe internal configuration of a brulshback mold for receiving theexposed ends of a plurality of said tufts retained in said pickingelements and for fusing said end to form a brushback of fusedfilamentary material having integral tufts of filaments extendingtherefrom, so that when said picking elements are simultaneouslyinserted into the-apertures in said stock box to pick a plurality oftufts, and withdrawn from said box through said apertures, with tuftsretained therein the end portions of said tufts extending from saidpicking elements may be simultaneously inserted into said recess untilsaid end portions fuse and form a brushback of fused filamentarymaterial hav-ing integral tufts extending therefrom.

31. Apparatus for assemlbling synthetic filament tufts having a fusedend portion for mounting on a brushback :omprising:

a stock box at a first station for supporting a plurality ofcut-to-length synthetic filaments in a parallel, stacked relationship,said box having at least one aperture therein for exposing the ends 'ofa plurality of said filaments;

least one hollow picking element having an open, filament-receiving endand a closed, tuft-trimming end, the open end of said element adapted tobe inserted into said box through the aperture and to receive an end andcentral portion of a plurality of filaments therein, forming a tuft;

retaining means carried by said picking element for retaining said tuftof filaments therein whensaid element is withdrawn from said stock boxthrough the aperture;

heated mold means at a second station having at least one tuft-receivingrecess therein for receiving an end portion of said tuft retained insaid picking element and for fusing said end to forma tuft of filamentsextending from an integral fused base adapted to be mounted on abrushback;

said picking element adapted to be moved to the first station and'subsequently to be moved to the second station so that said element maybe moved tothe first station, inserted into said stockbox through saidaperture to pick a tuft of filaments, withdrawn from said box throughsaid aperture with said tuft retained therein; moved to said secondstation, and the end portion'of said tuft extending from said pickingelement inserted into the recess of said heated mold means'to fuse saidend portion for mounting on a brushback.

32. The device of claim 31 wherein said stock box has a plurality ofapertures; said heated mold means has a plurality of recesses, theapertures and recesses being arranged in a pre-selected configuration;and a plurality of picking elements are provided; said elements adaptedto be simultaneously inserted -into said box through 'said apertures topick a plurality of tufts from said stock box; and subsequently tosimultaneously insert the end portions of said tufts extending from saidpicking elements into said recesses to fuse the end portions formounting on a brushback.

33. The device of claim 31 further comprising means for supporting abrushback having a plurality of tuft-receiving holes therein at a thirdstation so that the fused end portion of said tuft may be withdrawn fromthe recess in said heated moldmeans and inserted into a hole in saidbrushback before said fused end cools so that said 70 30 tuft end coolsin said hole conforming tothe internal confines thereof to retain saidtuft in said brushback.

34. The device of claim 32 further comprising means for supporting abrushback havingra plurality of tuft-receiving holes therein at a thirdstation so that the .fused end portions of said tufts may be withdrawnfromI the recesises in said heated mold means and inserted into holes insaid brushback before said fused ends cool so that said tuft ends coolin said holes conforming to the `internal confines thereof to retainsaid-tufts in said brushback.

35. Apparatus for aissembling a plurality of filament tufts to form abrushback having said tufts extending from an integral back of Ifusedflamentary material comprising:

a stock box at a first station for supporting a plurality ofcut-to-le-ngth synthetic filaments .in a parallel, stacked relationship,said. box having a plurality of apertures therein for exposing the endsof 'a plurality of filaments; 1- t. a plurality of hollow pickingelements each of said elements having an open filament-receiving end anda closed tuft-trimming end, the open end of eachelement adapted to beinserted into said box through the aperture and to receive an end andcentral portion of a plurality of filaments therein forming a tuft; .kretaining means carried by each of said picking elements for retainingsaid tufts of filaments therein when said element is 'withdrawn fromsaid box through the aperture; d heated mold means at a second stationhaving atuftf receiving rece'ss, said recess having the internal con-`figuration of a brushback mold for receiving the exposed ends of aplurality of said tufts retained in said picking elements and for fusingsaid ends to form a brushback of fused filamentary material havingintegral tufts 'of filaments extending therefrom; said picking elementsadaptedto be 'simultaneously inserted into the apertures in said stockbox to pick a plurality of tufts, and withdrawn with said retained tuftsfrom said box through said apertures;

i said elements also adapted to insert the end portions of said tuftsextending therefrom simultaneously into said recess until said endportions fuse and forml a brushback of fused jilamentary material havingintegral tufts extending therefrom.

References Cited g The following references, cited yby the Examiner, are

GRANVILLE Y. CUSTERJR., Primary Examiner oL-s, 7, 21,

-U.s. c1. X.R.

